5S

THE SECRET TO
JAPANESE SUCCESS
m „HAT PROBLEMS DO U COMMONLY
ENCOUNTER AT YOUR „ORKPLACE

m HIGH ABSENTEEISM
m HIGH TURNOVER
m DEMOTIVATED EMPLOYEES
m DISORDERED/ CLUTTERED
ENVIRONMENT
m MISTAKES/ERRORS
m THE SOLUTION TO ALL THESE
PROBLEMS IS

5S
 5S

HOUSEKEEPING TECHNIQUE

PRODUCTIVITY AND SAFETY

ENHANCEMENT TECHNIQUE
 IDEA BEHIND 5S
m IN ORDER TO ACHIEVE HIGH
LEVELS OF QUALITY, SAFETY,AND
PRODUCTIVITY, „ORKERS MUST
HAVE A CONDUCIVE „ORKING
ENVIRONMENT
 „HAT IS 5S?
m Developed by the Japanese
m Housekeeping System
m Helps Create a Better „orking
Environment and a Consistently
High Quality Process
 M
 


m SEIRI ± Organisation/Sort out
m SEITON ± Orderliness/Systemize
m SEISO ± The Cleaning/Shining
m SEIKETSU ± STANDARDIZE
m SHITSUKE - Sustain/Discipline
 DISCOVERY OF 5S

m Thirty years ago researchers started

studying the secret of success of
Japanese manufacturing companies
m 5S turned out to be the most
impressive "secret"
m The factories were so well organized
that abnormal situations were readily
apparent
 DISCOVERY OF 5S

m Equipments were so clean and well

maintained that any problem such
as a loose bolt or leaking oil could
be easily seen
m This passion of cleanliness and
orderliness became a hallmark of
Japanese organizations
 
 

m If tools and materials are conveniently
located in uncluttered work areas

m Operators spend less time looking for

items
m This leads to higher workstation
efficiency, a fundamental goal in mass
production
 
 

m A clean and tidy workplace leads
to greater well being and increased
motivation

m Company image improves

 
 


m Health and Safety is ensured

m Machine maintenance
m Quality
m Productivity
m Lean Manufacturing
 
 

m RESULTS IN A PLACE EASIER TO
MANAGE
m SMOOTH „ORKING NO
OBSTRUCTION
m NO DEVIATION, NO PROBLEMS

m B/C EVERYONE KNO„S „HERE THE

THINGS ARE SPPOSEDF TO BE
 
 

m TIME SAVING
m QUICK RETRIEVAL
m ACCIDENTS & MISTAKES
MINIMIZED
m INCREASES SPACE
m CREATES „ORKPLACE
O„NERSHIP
 
 

m FOUNDATION OF ALL QC TOOLS

m CONTINUOUS QUALITY
IMPROVEMENT
m LEAN MANUFACTURING
m KINDERGARTEN OF QUALITY
TOOLS & TECHNIQUES
 
 

m VISUAL MANAGEMENT SYSTEM

m VISUAL CONTROL TO SEE THE

ABNORMALITIES
m SIMPLE SIGNALS THAT PROVIDE AN
UNDERSTANDING OF THE CONDITION(
NORMAL/ ABNORMAL)
m A LOOK AT THE PROCESS REVEALS ITS
DIRECTION (RIGHT/„RONG-
 Lean Production

m The latest incarnation of JIT

m Based on Toyota Production SystemD
m „aste elimination
m „idely used in automotive
manufacturing & other repetitive mfg.
It¶s the elimination of waste Everywhere ±
while adding customer value«

It¶s a þ
 & commitment to

achieve a 
 

 
that¶s focused on your

þ
 achieved
by simplifying and 



þ

all 
 @

 

  
Lean production 




 
 



, which
is critical

It also 
 by improving
productivity & quality, reducing lead
times, and freeing huge amounts of
resources.
@
 
 
  
For example, lean production 

 










  so companies can

1. Add product lines

2. In-source component production
3. Increase output of existing products
without acquiring new facilities.
KINERGARTEN OF ALL THE QC
TOOLS

m 5S IS THE STARTING POINT OF

ALL THE QC TOOLS

m COULD BE SAID AS THE PRE-

REQUISITE OF ALL QC TOOLS
METHODOLOGY
OF 5S
èDM
-
m Decide what you need

m Remove unnecessary clutter

m All tools, gauges, materials, classified

and then stored

m Remove items which are broken,

unusable or only occasionally used
 Ú


RED TAG TECHNIQUE

m GIVE STAFF RED LABELS

m ASK STAFF TO GO THROUGH
EVERY ITEM IN THE „ORK PLACE
m ASK IF NEEDED & THOSE THAT
ARE NEEDED,IN „HAT QUANTITY
m NOT NEEDED RED TAG IT
m STORE IN THE RED TAG AREA
 Ú



For wavering items

m PLACE THE SUSPECTED ITEMS IN

THE RED TAG AREA FOR ONE
„EEK
m ALLO„ THE STAFF TO
REEVALUATE THE NEEDED ITEMS
m AT THE END OF „EEK THOSE
„HO NEED ITEMS SHOULD BE
RETURNED
M
|

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| 



2. ORDERLINESS(SEITON)

m ONCE YOU HAVE ELIMINATED ALL

THE UNNEEDED ITEMS

m NO„ TURN TO THE LEFT OVER

ITEMS
ORDERLINESS(SEITON)

Organise layout of tools and

equipment
±Designated locations
±Use tapes and labels
±Ensure everything is
available as it is needed and
at the ³point of use´
ORDERLINESS(SEITON)
„orkplace Checkpoints:-
m Positions of aisles and storage places
clearly marked?
m Tools classified and stored by frequency
of use?
m Pallets stacked correctly?
m Safety equipment easily accessible?
m Floors in good condition?
3. SEISO (CLEAN/SHINE)
m Create a spotless workplace

m Identify and eliminate causes of

dirt and grime ± remove the need
to clean

m Sweep, dust, polish and paint

SEISO (CLEAN/SHINE)

m Divide areas into zones

m Define responsibilities for cleaning

m Tools and equipment must be owned by

an individual

m Focus on removing the need to clean

. SEIKETSU (STANDARDISE)

m Generate a maintenance system for the

first three
m Develop procedures, schedules,
practices
m Continue to assess the use and disposal
of items
m Regularly audit using checklists and
measures of housekeeping
m Real challenge is to keep it clean
D M
M 

-
m Means inoculate courtesy & good habits
m Driving force behind all 5S
m Deming¶s point number 1: Constancy of
purpose
m Make it a way of life
m Part of health and safety
m Involve the whole workforce*
m Develop and keep good habits
LITMUS TEST FOR 5S
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Cont.
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